That panel looks nice. Masonite is not my favorite material. . . if you could get 1/8" baltic birch, that stuff is really the shit for what you're doing- around here the hardwood/cabinet maker supply place has it for $10 per 5'x5' sheet. The other option is (nominal) 1/4" birch ply in 4x8 sheets, it's usually more like 3/16" or even a bit thinner, it's definitely not 1/4".

Have you tried any panels with a thin foam behind the fabric or with the padding you got?

The local lumberyard has 1/4" ply (which is 3/8) but it is quite a bit heavier than the masonite and not nearly as flexible (I need to be able to match the curves of the ceiling/walls).

We haven't tried any foam backing yet. Apparently OSV uses 1/8" ply with 1/8" closed cell foam glued to it.. then the fabric.. that said I can't find 1/8" closed cell foam fabric sheet anywhere locally and am hesitant to order $100+ worth of the stuff without testing it first.

The local lumberyard has 1/4" ply (which is 3/8) but it is quite a bit heavier than the masonite and not nearly as flexible (I need to be able to match the curves of the ceiling/walls).

We haven't tried any foam backing yet. Apparently OSV uses 1/8" ply with 1/8" closed cell foam glued to it.. then the fabric.. that said I can't find 1/8" closed cell foam fabric sheet anywhere locally and am hesitant to order $100+ worth of the stuff without testing it first.

Chicken & Egg.

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Yeah. All I can say is that if there's a local place that does hardwood/cabinet grade plywood, that's where I'd head to look for some nice 1/8" ply. I'd send you some, but I get the feeling that shipping plywood is not going to be economical

I see a lot of stuff packed in the thin (1/16 or 1/8") closed cell white foam, especially appliance parts. Maybe some of that would give you an idea of the look if you thought you wanted to try it. And These guys have 1/8" foam pretty cheap.

I've been googling trying to find any source but no luck. I need to make a cabinet maker friend to find his supplier.

.mobile

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Try "bending ply", "wiggle wood", "wacky wood".

Columbia Forest Products and some other companies make it. I've used it as a substrate for veneered curved aprons for furniture. The stuff can be rolled up and shipped in a square box. It bends in only one direction. You can choose it to bend either the long way or the other way.

Darn strange Ed, I found some 1/8 at the Broomfield Lowes. I cut them to fill the whole door as I think it looks cleaner, then used those badass rivnuts to hold it in place. Worked out well methinks. I wonder if I'll be doing it all again in a years time!